Sulfide solid-state cell

ABSTRACT

A rechargeable sulfide solid-state cell. The sulfide solid-state cell may include: a cathode active material layer containing at least one kind of cathode active material selected from LiCoPO 4  and LiFePO 4 ; an anode active material layer; a sulfide-based solid electrolyte layer containing a sulfide-based solid electrolyte and being disposed between the cathode active material layer and the anode active material layer; and a blocking layer containing at least one kind of phosphoric acid compound with a NASICON structure, covering at least a part of the surface of the cathode active material and/or the surface of the sulfide-based solid electrolyte, being disposed between the cathode active material layer and the sulfide-based solid electrolyte layer, and being configured to prevent the cathode active material layer from contact with the sulfide-based solid electrolyte layer, the phosphoric acid compound being selected from LATP and LAGP.

TECHNICAL FIELD

The disclosure relates to a sulfide solid-state cell.

BACKGROUND

In the field of solid-state cells in which solid electrolytes are usedin place of liquid electrolytes, there has been an attempt to focus onelectrode active materials and solid electrolyte materials and improvethe performance of solid-state cells (for example, Patent Documents 1and 2).

An all-solid-state cell is disclosed in Patent Document 1, which usesLiCoPO₄ as active material.

A technique relating to sulfide-based solid electrolytes is disclosed inPatent Document 2.

Patent Document 1: Japanese Patent Application Laid-Open (JP-A) No.2009-140911

Patent Document 2: JP-A No. 2015-032529

When LiCoPO₄ with an olivine structure and/or LiFePO₄ with an olivinestructure is used as the cathode active material of a sulfidesolid-state cell, there is a problem that the cell is not rechargeable.

SUMMARY

The disclosed embodiments were achieved in light of the abovecircumstance. An object of the disclosed embodiments is to provide arechargeable sulfide solid-state cell.

In a first embodiment, there is provided a sulfide solid-state cell. Thesulfide solid-state cell comprises: a cathode active material layercontaining at least one kind of cathode active material selected fromLiCoPO₄ and LiFePO₄; an anode active material layer; a sulfide-basedsolid electrolyte layer containing a sulfide-based solid electrolyte andbeing disposed between the cathode active material layer and the anodeactive material layer; and a blocking layer containing at least one kindof phosphoric acid compound with a NASICON structure, covering at leasta part of the surface of the cathode active material and/or the surfaceof the sulfide-based solid electrolyte, being disposed between thecathode active material layer and the sulfide-based solid electrolytelayer, and being configured to prevent the cathode active material layerfrom contact with the sulfide-based solid electrolyte layer. Thephosphoric acid compound is selected from Li_(x)Al_(y)Ti_(z)(PO₄)₃(where x is a number that satisfies 1≦x≦2.5; y is a number thatsatisfies 0<y≦1; and z is a number that satisfies 1≦z≦2.5) andLi_(x)Al_(y)Ge_(z)(PO₄)₃ (where x is a number that satisfies 1≦x≦2.5; yis a number that satisfies 0<y≦1; and z is a number that satisfies1≦z≦2.5).

The blocking layer may cover a contact surface of the cathode activematerial layer with the sulfide-based solid electrolyte layer.

According to the disclosed embodiments, a rechargeable sulfidesolid-state cell is provided.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings,

FIG. 1 is a view of an example of the sulfide solid-state cell accordingto an embodiment;

FIG. 2 is a view showing the XRD evaluation result of LATP in Example 1;

FIG. 3 is a view showing the XRD evaluation result of LAGP in Example 2;

FIG. 4 is a view showing the CV evaluation result of Example 1;

FIG. 5 is a view showing the CV evaluation result of Example 2;

FIG. 6 is a view showing the CV evaluation result of Example 3;

FIG. 7 is a view showing the CV evaluation result of Comparative Example1;

FIG. 8 is a view showing the CV evaluation result of Comparative Example1;

FIG. 9 is a view showing the charge-discharge results of Example 1; and

FIG. 10 is a view showing the charge-discharge results of Example 2.

DETAILED DESCRIPTION

The sulfide solid-state cell of the disclosed embodiments comprises: acathode active material layer containing at least one kind of cathodeactive material selected from LiCoPO₄ and LiFePO₄; an anode activematerial layer; a sulfide-based solid electrolyte layer containing asulfide-based solid electrolyte and being disposed between the cathodeactive material layer and the anode active material layer; and ablocking layer containing at least one kind of phosphoric acid compoundwith a NASICON structure, covering at least a part of the surface of thecathode active material and/or the surface of the sulfide-based solidelectrolyte, being disposed between the cathode active material layerand the sulfide-based solid electrolyte layer, and being configured toprevent the cathode active material layer from contact with thesulfide-based solid electrolyte layer, the phosphoric acid compoundbeing selected from Li_(x)Al_(y)Ti_(z)(PO₄)₃ (where x is a number thatsatisfies 1≦x≦2.5; y is a number that satisfies 0<y≦1; and z is a numberthat satisfies 1≦z≦2.5) and Li_(x)Al_(y)Ge_(z)(PO₄)₃ (where x is anumber that satisfies 1≦x≦2.5; y is a number that satisfies 0<y≦1; and zis a number that satisfies 1≦z≦2.5).

LiCoPO₄ with an olivine structure and LiFePO₄ with an olivine structureare active materials with high potential; therefore, from the viewpointof chemical reactivity, their application to solid cells as a materialfor increasing cell energy density, is expected. However, a sulfidesolid-state cell including a cathode active material layer that containsLiCoPO₄ and/or LiFePO₄ as a cathode active material, is problematic inthat the cell is not rechargeable. The reason for this is considered tobe because a side reaction occurs between the sulfide-based solidelectrolyte and the LiCoPO₄ and/or LiFePO₄, producing a resistive layeron the surface of the LiCoPO₄ and/or the surface of the LiFePO₄ and anincrease in the resistance of an interface between the cathode activematerial and the sulfide-based solid electrolyte. That is, it isconsidered that during charge and discharge, the cobalt in the LiCoPO₄and the iron in the LiFePO₄ react with the sulfur in the sulfide-basedsolid electrolyte to produce a by-product.

However, it was found that the sulfide solid-state cell including thecathode active material layer that contains the LiCoPO₄ and/or LiFePO₄as the cathode active material, can be rechargeable by disposing theblocking layer between the cathode active material layer and thesulfide-based solid electrolyte layer.

The reason for this is considered to be because the LATP and LAGP have aNASICON structure. The NASICON structure is composed of a basic unitthat is composed of two octahedra and three tetrahedra, and it oftenincludes large spaces (bottleneck) in its crystal structure. Therefore,it is presumed that due to the NASICON structure, the diffusion of thesulfur contained in the sulfide-based solid electrolyte (sulfurelimination) can be inhibited. As a result, it is considered that achemical reaction between the sulfur and the cobalt and/or iron isinhibited, and the increase in the resistance of the interface due tothe formation of the resistive layer is inhibited.

It is also considered that by use of the LATP and LAGP as a material forthe blocking layer, both of which have the same PO₄ framework as LiCoPO₄and LiFePO₄, unintended reactions are less likely to occur at the timeof covering the surface of the cathode active material with the blockinglayer in a heated condition, compared to the case of using otheroxide-based solid electrolyte materials with no PO₄ framework (e.g.,Li₄Ti₅O₁₂ (LTO)) as a material for the blocking layer. As a result, itis considered that at the interface between the cathode active materialand the blocking layer, the production of different phases with highresistance is inhibited, and the increase in the resistance of theinterface can be inhibited.

As described above, it is presumed that charge and discharge of thesulfide solid-state cell is enabled by the effect of, at the interfacebetween the blocking layer and the sulfide-based solid electrolytelayer, inhibiting the diffusion of the sulfur contained in thesulfide-based solid electrolyte, which is an effect that is due to theNASICON structure, and the effect of inhibiting the production ofdifferent phases at the interface between the blocking layer and thecathode active material layer, which is an effect that is due to the PO₄framework.

According to the disclosed embodiments, the application of cathodeactive materials with an olivine structure to sulfide solid-state cellsis enabled and makes a significant contribution to an increase in theenergy density of solid cells.

FIG. 1 is a schematic sectional view of an example of the sulfidesolid-state cell according to an embodiment. The sulfide solid-statecell of the disclosed embodiments is not limited to this embodiment.

A sulfide solid-state cell 100 includes: a cathode active material layer11 containing a cathode active material; an anode active material layer12 containing an anode active material; a sulfide-based solidelectrolyte layer 13 being disposed between the cathode active materiallayer 11 and the anode active material layer 12 and being in contactwith the anode active material layer 12; a blocking layer 14 beingdisposed between the cathode active material layer 11 and thesulfide-based solid electrolyte layer 13; a cathode current collector 15for collecting current from the cathode active material layer 11; and ananode current collector 16 for collecting current from the anode activematerial layer 12.

-   (1) Cathode Active Material Layer

The cathode active material layer is a layer containing at least onekind of cathode active material selected from at least LiCoPO₄ andLiFePO₄.

In addition to LiCoPO₄ and LiFePO₄, the cathode active material may alsocontain LiMnPO₄, LiNiPO₄ and solid solutions thereof. The cathode activematerial may be particles.

The content of the cathode active material in the cathode activematerial layer is not particularly limited. From the viewpoint of cellcapacity, the content may be as large as possible. For example, thecontent of the cathode active material may be 10% by mass or more of thetotal mass (100% by mass) of the cathode active material layer, or itmay be in a range of 20% by mass to 90% by mass.

As needed, the cathode active material layer may contain at least one ofan electroconductive material and a binder.

The electroconductive material is not particularly limited, as long asit is able to increase the electroconductivity of the cathode activematerial layer. Examples include, but are not limited to, anelectroconductive carbonaceous material.

The electroconductive carbonaceous material is not particularly limited.From the viewpoint of the area or space of reaction sites, it may be acarbonaceous material with a high specific surface area. Morespecifically, the electroconductive carbonaceous material may have aspecific surface area of 10 m²/g or more, 100 m²/g or more, or 600 m²/gor more.

As the electroconductive carbonaceous material with a high specificsurface area, examples include, but are not limited to, carbon black(such as acetylene black and Ketjen black), activated carbon and carbonfibers (such as carbon nanotubes (CNT), carbon nanofibers andvapor-grown carbon fibers).

The specific surface area of the electroconductive material may bemeasured by the BET method, for example.

The content of the electroconductive material in the cathode activematerial layer may vary depending on the type of the electroconductivematerial. In general, when the total mass of the cathode active materiallayer is 100% by mass, the content of the electroconductive material maybe in a range of 1 to 30% by mass.

As the binder, examples include, but are not limited to, polyvinylidenefluoride (PVdF) and polytetrafluoroethylene (PTFE). The content of thebinder in the cathode active material layer is such a content that canfix the cathode active material, etc., and it may be as small aspossible. In general, when the total mass of the cathode active materiallayer is 100% by mass, the content of the binder may be in a range of 0to 10% by mass.

The thickness of the cathode active material layer may vary depending onthe application of the cell, etc. For example, the lower limit may be 2nm or more, or it may be 100 nm or more. The upper limit may be 1,000 μmor less, or it may be 500 μm or less.

As needed, the sulfide solid-state cell of the disclosed embodimentsincludes a cathode current collector for collecting current from thecathode active material layer. The cathode current collector may be acathode current collector with a porous or dense structure, as long asit shows desired electron conductivity. The cathode current collectormay be a cathode current collector with a porous structure such as amesh structure. As the form of the cathode current collector, examplesinclude, but are not limited to, a foil form, a plate form and a mesh(grid) form.

As the material for the cathode current collector, examples include, butare not limited to, metal materials such as stainless-steel, nickel,aluminum, iron, titanium, copper, gold, silver and palladium,carbonaceous materials such as carbon fibers and carbon papers, andhighly electron conductive ceramic materials such as titanium nitride.

The thickness of the cathode current collector is not particularlylimited. For example, it may be in a range of 10 to 1,000 μm, or it maybe in a range of 20 to 400 μm. An outer case to be described below mayalso function as the cathode current collector.

The cathode current collector may include a terminal that serves as aconnection to the outside.

As the method for producing the cathode active material layer, examplesinclude, but are not limited to, a method for roll-pressing a mixture ofthe cathode active material and, as needed, other components such as abinder, and a method for applying a slurry that contains the mixture anda solvent. As the solvent used for the preparation of the slurry,examples include, but are not limited to, acetone, ethanol andN-methyl-2-pyrrolidone (NMP). As the method for applying the slurry,examples include, but are not limited to, a screen printing method, agravure printing method, a die coating method, a doctor blade method, aninkjet method, a metal mask printing method, an electrostatic coatingmethod, a dip coating method, a spray coating method and a rollercoating method. In particular, the cathode active material layer can beformed by applying the slurry to the above-described cathode currentcollector or a carrier film, drying the applied slurry and, as needed,roll-pressing and/or cutting the dried slurry.

-   (2) Blocking Layer

The blocking layer may be a layer containing at least one kind ofphosphoric acid compound with a NASICON structure, covering at least apart of the surface of the cathode active material and/or the surface ofthe sulfide-based solid electrolyte, being disposed between the cathodeactive material layer and the sulfide-based solid electrolyte layer, andbeing configured to prevent the cathode active material layer fromcontact with the sulfide-based solid electrolyte layer, the phosphoricacid compound being selected from LATP (Li_(x)Al_(y)Ti_(z)(PO₄)₃ where xis a number that satisfies 1≦x≦2.5; y is a number that satisfies 0<y≦1;and z is a number that satisfies 1≦z≦2.5) and LAGP(Li_(x)Al_(y)Gez(PO₄)₃ where x is a number that satisfies 1≦x≦2.5; y isa number that satisfies 0<y≦1; and z is a number that satisfies1≦z≦2.5).

A reaction between the cathode active material and the sulfide-basedsolid electrolyte can be inhibited by disposing the blocking layer.

The blocking layer is not particularly limited, as long as it is a layerthat containing at least one kind of phosphoric acid compound with aNASICON structure, the phosphoric acid compound being selected from atleast LATP and LAGP. The blocking layer may be a layer composed of LATPor LAGP. In particular, the LATP may be Li_(1.5)Al_(0.5)Ti_(1.5)(PO₄)₃,and the LAGP may be Li_(1.5)Al_(0.5)Ge_(1.5)(PO₄)₃.

The blocking layer covers at least a part of the surface of the cathodeactive material and/or the surface of the sulfide-based solidelectrolyte. The blocking layer may cover a contact surface of thecathode active material layer with the sulfide-based solid electrolytelayer.

For the contact surface of the blocking layer with the cathode activematerial layer and/or the sulfide-based solid electrolyte layer, thecoverage of the cathode active material layer and/or the sulfide-basedsolid electrolyte layer with the blocking layer may be 40% or more, maybe 70% or more, or may be 90% or more.

When the cathode active material and/or the sulfide-based solidelectrolyte is particles, the coverage of the cathode active materialparticle surface and/or the sulfide-based solid electrolyte particlesurface with the blocking layer may be 40% or more, may be 70% or more,or may be 90% or more.

The coverage with the blocking layer can be qualitatively confirmed byuse of a transmission electron microscope (TEM) or X-ray photoelectronspectroscopy (XPS), for example.

When the cathode active material and/or the sulfide-based solidelectrolyte is particles, the diameter of the cathode active materialparticles and the sulfide-based solid electrolyte particles is notparticularly limited. The lower limit may be 1 nm or more, may be 10 nmor more, or may be 100 nm or more. The upper limit may be 100 mm orless, may be 10 mm or less, or may be 1 mm or less.

In the disclosed embodiments, the average particle diameter of particlesmay be calculated by a conventional method. An example of the method forcalculating the average particle diameter of particles is as follows.First, for a particle shown in an image taken by a transmission electronmicroscope (hereinafter referred to as TEM) or scanning electronmicroscope (hereinafter referred to as SEM) at an appropriatemagnification (e.g., 50,000× to 1,000,000×), the particle diameter iscalculated on the assumption that the particle is spherical. Such anaverage particle diameter calculation by TEM observation or SEMobservation is conducted on 200 to 300 particles of the same type, andthe average of the particles is considered as the average particlediameter.

The thickness of the blocking layer is not particularly limited. Thelower limit may be 1 nm or more, may be 10 nm or more, or may be 100 nmor more. The upper limit may be 1 μm or less, may be 500 nm or less, ormay be 200 nm or less.

If the thickness of the blocking layer is too large, due to the largethickness of the blocking layer, the resistance of the sulfidesolid-state cell may increase. On the other hand, if the thickness ofthe blocking layer is too small, a reaction between the cathode activematerial and the sulfide-based solid electrolyte may not be sufficientlyinhibited. The thickness can be obtained by image analysis using ascanning electron microscope (SEM) or transmission electron microscope(TEM).

The method for producing the blocking layer is not particularly limited.For example, the blocking layer may be produced by the following method:LATP and/or LAGP is dispersed in a dispersion medium to prepare aslurry, and the slurry is applied onto the cathode active material layerand/or the sulfide-based solid electrolyte layer, dried androll-pressed, thereby producing the blocking layer.

The dispersion medium is the same as the dispersion medium used for theproduction of the cathode active material layer described above.

As the method for applying the slurry, examples include, but are notlimited to, a doctor blade method, a metal mask printing method, anelectrostatic coating method, a dip coating method, a spray coatingmethod, a roller coating method, a gravure coating method and a screenprinting method. Of them, an electrostatic coating method may be used.

When the cathode active material and/or the sulfide-based solidelectrolyte is particles, the blocking layer may be formed on thecathode active material particle surface and/or the sulfide-based solidelectrolyte particle surface, by a tumbling/fluidizing coating method(sol-gel method), a mechanofusion method, a chemical vapor deposition(CVD) method or a physical vapor deposition (PVD) method, for example.

-   (3) Sulfide-Based Solid Electrolyte Layer

The sulfide-based solid electrolyte layer may be a layer being disposedbetween the cathode active material layer and the anode active materiallayer and being in contact with the anode active material layer. Thesulfide-based solid electrolyte layer may contain at least asulfide-based solid electrolyte.

The sulfide-based solid electrolyte is not particularly limited, as longas it contains a sulfur element (S) and shows ion conductivity.

When the sulfide solid-state cell of the disclosed embodiments is asulfide solid-state lithium cell, examples include, but are not limitedto, Li₂S—P₂S₅, Li₂S—P₂S₅—LiI, Li₂S—P₂S₅—Li₂O, Li₂S—P₂S₅—Li₂O—LiI,Li₂S—SiS₂, Li₂S—SiS₂—LiI, Li₂S—SiS₂—LiBr, Li₂S—SiS₂—LiCl,Li₂S—SiS₂—B₂S₃—LiI, Li₂S—SiS₂—P₂S₅—LiI, Li₂S—B₂S₃, Li₂S—P₂S₅—Z_(m)S_(n)(where m is a positive number; n is a positive number; and Z is any ofGe, Zn and Ga), Li₂S—GeS₂, Li₂S—SiS₂—Li₃PO₄, and Li₂S—SiS₂—Li_(x)MO_(y)(where x is a positive number; y is a positive number; and M is any ofP, Si, Ge, B, Al, Ga and In). Of these electrolytes, “Li₂S—P₂S₅” means asulfide-based solid electrolyte material composed of a raw materialcomposition that contains Li₂S and P₂S₅. The same applies to the others.

The sulfide-based solid electrolyte may be particles, a sulfide glass,or a crystallized sulfide glass obtained by heating the sulfide glass.

The content of the sulfide-based solid electrolyte in the sulfide-basedsolid electrolyte layer may be 60% by mass or more, may be 70% by massor more, or may be 80% by mass or more, for example. The sulfide-basedsolid electrolyte layer may also contain a binder, or it may be composedof only the sulfide-based solid electrolyte. The binder used in thesulfide-based solid electrolyte layer is the same as the above-describedcathode active material layer. The thickness of the sulfide-based solidelectrolyte layer may be in a range of 0.1 μm to 1,000 μm, or it may bein a range of 0.1 μm to 300 μm, for example.

The method for producing the sulfide-based solid electrolyte layer isnot particularly limited. The sulfide-based solid electrolyte layer maybe produced as follows: the sulfide-based solid electrolyte is preparedin the form of a pressed powder, placed on the blocking layer or theanode active material layer and then pressurized, thereby producing astack of the sulfide-based solid electrolyte layer and the blockinglayer or the anode active material layer.

-   (4) Anode Active Material Layer

The anode active material layer may be a layer containing at least ananode active material. As needed, it may contain at least one of a solidelectrolyte material, an electroconductive material and a binder.

Due to containing the solid electrolyte material, the anode activematerial layer may be an anode active material layer with high ionconductivity. The solid electrolyte material used in the anode activematerial layer may be the same material as the sulfide-based solidelectrolyte used in the above-described sulfide-based solid electrolytelayer.

As the anode active material, examples include, but are not limited to,a metal active material and a carbon active material.

As the metal active material, examples include, but are not limited to,In, Al, Si and Sn. As the carbon active material, examples include, butare not limited to, mesocarbon microbeads (MCMB), highly-orientedpyrolytic graphite (HOPG), hard carbon and soft carbon.

The content of the anode active material in the anode active materiallayer may be 10% by mass or more, or it may be in a range of 20% by massto 90% by mass, for example.

The electroconductive material and binder used in the anode activematerial layer are the same as the above-described cathode activematerial layer. The thickness of the anode active material layer may bein a range of 0.1 μm to 1,000 μm, for example.

As needed, the sulfide solid-state cell of the disclosed embodimentsincludes an anode current collector for collecting current from theanode active material layer. The material for the anode currentcollector is not particularly limited, as long as it iselectroconductive. Examples include, but are not limited to,stainless-steel, nickel, copper and carbon. As the form of the anodecurrent collector, examples include, but are not limited to, a foilform, a plate form and a mesh form. The thickness of the anode currentcollector is not particularly limited. For example, it may be in a rangeof 10 to 1,000 μm, or it may be in a range of 20 to 400 μm. Thebelow-described outer case may also function as the anode currentcollector.

The anode current collector may include a terminal that serves as aconnection to the outside.

The method for producing the anode active material layer is notparticularly limited. For example, the anode active material layer maybe produced by the following method: a mixture of the anode activematerial and, as needed, other components such as a binder, is dispersedin a dispersion medium to prepare a slurry, and the slurry is appliedonto the anode current collector, dried and roll-pressed, therebyproducing the anode active material layer.

The dispersion medium and the method for applying the slurry are thesame as the above-described method for producing the cathode activematerial layer.

-   (5) Other Components

In general, the sulfide solid-state cell of the disclosed embodimentsincludes an outer case for housing the cathode active material layer,the anode active material layer, the sulfide-based solid electrolytelayer and so on. As the form of the outer case, examples include, butare not limited to, a coin form, a flat plate form, a cylindrical formand a laminate form.

The material for the outer case is not particularly limited, as long asit is stable to electrolytes. Examples include, but are not limited to,metals such as SUS, and resins such as polypropylene, polyethylene andacrylic resins. When the outer case is composed of a metal, only thesurface of the outer case may be composed of a metal, or the whole outercase may be composed of a metal.

As the sulfide solid-state cell of the disclosed embodiments, examplesinclude, but are not limited to, a lithium cell, a sodium cell, amagnesium cell and a calcium cell. Of them, the sulfide solid-state cellmay be a lithium cell. Also, the sulfide solid-state cell of thedisclosed embodiments may be a primary cell or a secondary cell. Ofthem, the sulfide solid-state cell of the disclosed embodiments may be asecondary cell, because it can be repeatedly charged and discharged andis useful as a cell that can be equipped in a vehicle, for example.

EXAMPLES Example 1 [Cathode Active Material]

A solution for cathode active material was obtained by dissolvinglithium ethoxide (6.25 mmol/L), cobalt nitrate (5 mmol/L) and phosphoricacid (5 mmol/L) in a mixed solvent of dehydrated ethanol and butylcarbitol mixed at a volume ratio of 1:2 (50 mL).

The solution was filled into an electrostatic spraying device andsprayed onto a Pt foil in the following conditions to form a layer:

-   -   Applied voltage: 15,000 V    -   Flow rate: 50 μl/min    -   Substrate temperature: 300° C.    -   Outer diameter of nozzle: 100 μm

The thus-obtained thin film was subjected to an annealing treatment at600° C. for 5 hours in the air, thereby obtaining an LiCoPO₄ film.

[Formation of Blocking Layer]

A solution for blocking layer was obtained by dissolving lithiumethoxide (9.4 mmol/L), aluminum isopropoxide (2.5 mmol/L), titaniumisopropoxide (7.5 mmol/L) and phosphoric acid (15 mmol/L) in a mixedsolvent of dehydrated ethanol and butyl carbitol mixed at a volume ratioof 1:2 (50 mL).

The solution was filled into the electrostatic spraying device andsprayed onto the Pt foil (on which the LiCoPO₄ film was formed) in thefollowing conditions to form a layer:

-   -   Applied voltage: 15,000 V    -   Flow rate: 50 μl/min    -   Substrate temperature: 200° C.    -   Outer diameter of nozzle: 100 μm

The thus-obtained thin film was subjected to an annealing treatment at600° C. for 5 hours in the air, thereby obtaining the LiCoPO₄ filmcovered with an LATP film (blocking layer).

[X-ray Diffraction Measurement]

X-ray diffraction (XRD) measurement was conducted using thethus-obtained LiCoPO₄ film covered with the LATP film (blocking layer).The XRD measurement was conducted in an inert atmosphere. The result isshown in FIG. 2.

The XRD measurement conditions are as follows:

-   -   Device: Ultima IV (manufactured by Rigaku Corporation)    -   X-ray source: CuKα rays    -   Tube voltage−tube current: 40 kV-200 mA    -   Step width: 0.01 deg    -   Measuring rate: 1 sec/step

As shown in FIG. 2, it was confirmed that in the X-ray diffraction usingCuKα rays, the LATP has diffraction peaks at positions of 21°, 25° and30° of diffraction angle 2θ. These peaks may be in a range of 0.50°(especially 0.30°, particularly) 0.10° either side of the positions of21°, 25° and 30°, since a slight change in crystal lattice may occur dueto material composition, etc.

[Anode Active Material]

In ethanol (50 mL), lithium ethoxide (15 mmol/L) and titaniumtetraisopropoxide (15 mmol/L) were mixed to obtain a solution for anodeactive material.

The solution was filled into the electrostatic spraying device andsprayed onto a Pt foil in the following conditions to form a film:

-   -   Applied voltage: 15,000 V    -   Flow rate: 50 μl/min    -   Substrate temperature: 200° C.    -   Outer diameter of nozzle: 100 μm

The thus-obtained thin film was subjected to an annealing treatment at600° C. for 5 hours in the air, thereby obtaining an LTO film.

[Solid Electrolyte Material]

As a sulfide-based solid electrolyte material, 75Li₂S—25P₂S₅ particleswere taken.

[Production of Solid-State Cell]

First, as the sulfide-based solid electrolyte layer, the 75Li₂S—25P₂S₅particles was formed in the form of a pressed powder. Next, the LiCoPO₄film covered with the LATP film (blocking layer) was disposed on oneside of the pressed powder, and the LTO film was disposed on the otherside of the pressed powder. The resulting product was subjected to flatpressing at a pressure of 4 ton/cm² (≈392 MPa) for a pressing time ofone minute, thereby obtaining a laminate. For the thus-obtainedlaminate, the thickness of the cathode active material layer (theLiCoPO₄ film) was 500 nm; the thickness of the blocking layer (the LATPfilm) was 100 nm; the thickness of the anode active material layer (theLTO film) was 500 nm; and the thickness of the sulfide-based solidelectrolyte layer (the pressed powder of the 75Li₂S—25P₂S₅ particles)was 300 μm. This laminate was pressed at a pressure of 2 N in thelaminating direction, thereby producing a sulfide solid-state cell.

Example 2

A sulfide solid-state cell was produced in the same manner as Example 1,except that in the above “Formation of blocking layer”, 7.5 mmol/L ofgermanium isopropoxide was used in place of the titanium isopropoxide,thereby obtaining an LiCoPO₄ film covered with an LAGP film.

[X-ray Diffraction Measurement]

X-ray diffraction (XRD) measurement was conducted using thethus-obtained LiCoPO₄ film covered with the LAGP film. The XRDmeasurement was conducted in an inert atmosphere. The result is shown inFIG. 3.

The XRD measurement conditions are the same as Example 1.

As shown in FIG. 3, it was confirmed that in the X-ray diffraction usingCuKα rays, the LAGP has diffraction peaks at positions of 21°, 25° and30° of diffraction angle 2θ. These peaks may be in a range of 0.50°(especially 0.30°, particularly 0.10°) either side of the positions of21°, 25° and 30°, since a slight change in crystal lattice may occur dueto material composition, etc.

Example 3

A sulfide solid-state cell was produced in the same manner as Example 1,except that in the above “Cathode active material”, 5 mmol/L of ironnitrate was used in place of the cobalt nitrate, and in the above“Formation of blocking layer”, an LiFePO₄ film covered with an LATP film(blocking layer) was obtained.

Comparative Example 1

A sulfide solid-state cell was produced in the same manner as Example 1,except that the above “Formation of blocking layer” was not conducted,and an LiCoPO₄ film not covered with an LATP film was used as thecathode active material layer of the sulfide solid-state cell.

[CV Measurement]

Cyclic voltammetry (CV) measurement was conducted using the sulfidesolid-state cells produced in Examples 1 to 3 and Comparative Example 1.

The CV measurement conditions are as follows:

-   -   Atmosphere: Ar atmosphere    -   Sweep rate: 0.1 mV/sec (Examples 1 and 3, Comparative Example        1), 0.5 mV/sec (Example 2)    -   Number of cycles: 3    -   Potential sweep range: a range of 2.6 to 3.5 V (vs. RHE)        (Example 1), a range of 1.5 to 3.8 V (vs. RHE) (Example 2), a        range of 1.0 to 2.6 V (vs. RHE) (Example 3), a range of 2.5 to        3.5 V (vs. RHE) (Comparative Example 1)

The CV measurement results are shown in FIG. 4 (Example 1, potentialrange 2.0 to 4.0 V (vs. RHE)), FIG. 5 (Example 2, potential range 0.0 to4.0 V (vs. RHE)), FIG. 6 (Example 3, potential range 0.5 to 3.5 V (vs.RHE)), FIG. 7 (Comparative Example 1, potential range 0.0 to 4.0 V (vs.RHE)) and FIG. 8 (Comparative Example 1, potential range 2.0 to 4.0 V(vs. RHE)).

[Charge-Discharge Test]

Using the sulfide solid-state cells produced in Examples 1 and 2, acharge and discharge test was conducted at a charge-discharge current of3 μA. Each cell was charged to 3.8 V (vs. RHE) and discharged to 1.5 V(vs. RHE). The results of the test are shown in FIG. 9 (Example 1) andFIG. 10 (Example 2).

As shown in FIGS. 7 and 8, for the sulfide solid-state cell ofComparative Example 1, which is a cell not including the blocking layer(LATP film), any oxidation-reduction reaction whose average voltage isaround 3.2 V, was not confirmed. As shown in FIG. 7, it was confirmedthat a large oxidation current flowed at around 2 V. Therefore, it ispresumed that a side reaction proceeded before the potential of Liinsertion/extraction in the LiCOPO₄, so that a charge-discharge reactionof the LiCoPO₄ could not be confirmed.

Meanwhile, as shown in FIG. 4, for the sulfide solid-state cell ofExample 1, which is a cell including the blocking layer (LATP film), twopairs of oxidation-reduction peaks specific to LiCoPO₄ were confirmed.As shown in FIG. 9, it was confirmed that the sulfide solid-state cellof Example 1 charged and discharged.

As shown in FIG. 5, for the sulfide solid-state cell of Example 2, whichis a cell including the blocking layer (LAGP film), oxidation-reductionpeaks specific to LiCoPO₄ were confirmed. As shown in FIG. 10, it wasconfirmed that the sulfide solid-state cell of Example 2 charged anddischarged.

Furthermore, as shown in FIG. 6, for the sulfide solid-state cell ofExample 3, which is a cell including the blocking layer (LATP film),oxidation-reduction peaks specific to LiFePO₄ were confirmed. Therefore,it is presumed that the sulfide solid-state cell of Example 3 is able tocharge and discharge.

It will be appreciated that the above-disclosed features and functions,or alternatives thereof, may be desirably combined into differentcompositions, systems or methods. Also, various alternatives,modifications, variations or improvements may be subsequently made bythose skilled in the art. As such, various changes may be made withoutdeparting from the spirit and scope of this disclosure.

1. A sulfide solid-state cell, wherein the sulfide solid-state cellcomprises: a cathode active material layer containing at least one kindof cathode active material selected from LiCoPO₄ and LiFePO₄; an anodeactive material layer; a sulfide-based solid electrolyte layercontaining a sulfide-based solid electrolyte and being disposed betweenthe cathode active material layer and the anode active material layer;and a blocking layer containing at least one kind of phosphoric acidcompound with a NASICON structure, covering at least a part of thesurface of the cathode active material and/or the surface of thesulfide-based solid electrolyte, being disposed between the cathodeactive material layer and the sulfide-based solid electrolyte layer, andbeing configured to prevent the cathode active material layer fromcontact with the sulfide-based solid electrolyte layer, the phosphoricacid compound being selected from Li_(x)Al_(y)Ti_(z)(PO₄)₃ (where x is anumber that satisfies 1≦x≦2.5; y is a number that satisfies 0<y≦1; and zis a number that satisfies 1≦z≦2.5) and Li_(x)Al_(y)Ge_(z)(PO₄)₃ (wherex is a number that satisfies 1≦x≦2.5; y is a number that satisfies0<y≦1; and z is a number that satisfies 1≦z≦2.5).
 2. The sulfidesolid-state cell according to claim 1, wherein the blocking layer coversa contact surface of the cathode active material layer with thesulfide-based solid electrolyte layer.